Multi-piece vehicle interior trim panel

ABSTRACT

The present invention provides a method for making a multi-piece vehicle interior trim panel. In at least one embodiment, the method comprises providing a major panel having a major substrate, a sprayed urethane major skin layer disposed over at least a portion of the major substrate, and a foam layer between the major substrate and the major skin layer. The method further includes forming a minor panel by spraying polyurethane material proximate a relatively small mold surface to form a sprayed urethane minor skin layer, spraying expandable polyurethane material onto the minor skin layer to form a first resilient layer, placing a mounting substrate onto the first resilient layer, and spraying expandable polyurethane material onto the first resilient layer and the mounting substrate to form a second resilient layer. The method further comprises removing the minor panel from the mold and securing the minor panel to the major panel portion.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to multi-piece vehicle interior trim panels.

2. Background Art

The use of interior trim panels in automotive applications is relativelywell known. One relatively typical vehicle interior trim panel comprisesa relatively rigid substrate having a flexible thin plastic skindisposed over at least an interior facing portion of a surface of thesubstrate. Spraying material, such as a polyurethane composition, onto amold provides a skin having several advantages. When a softer touch forthe panel is desired, foam has been provided between the substrate andthe skin. The distance, or space, between the skin and the substrate isknown as the package space (X).

A common method of providing the foam is to employ the use of a foam inplace process. Various areas of a trim panel of a vehicle, such as theborder area below and/or around the center stack of an instrument panel,may have a relatively short height (H) and/or a relative small packagespace (X). For portions of trim panels having a height (H) of less than12 mm and/or a package space (X) of less than 5 mm, the typical foam inplace process may have difficulty being employed. This is because foamflow through these areas having a relatively small height (H) and/orpackage space (X) can be hindered and unreliable.

As such, it can be difficult to provide a soft touch sprayed skin paneldue to the unreliability and difficulties with the foam in place processfor panels having portions with a relatively small height (H) and/or apackage space (X). A relatively common result is that, due to the poorfoam coverage in these areas, the panel can have uneven softness zones.As part of overall craftsmanship, it is desirable to provide a softtouch sprayed skin panel having relatively even softness zones withconsistent skin material to ensure consistent color, gloss and grainmatch.

SUMMARY OF THE INVENTION

The present invention provides a method for making a multi-piece vehicleinterior trim panel.

In at least one embodiment, the method comprises providing a major panelhaving a major substrate, a sprayed urethane major skin layer disposedover at least a portion of the major substrate, and a layer of foambetween the major substrate and the major skin layer. The major panelportion may have at least one mounting opening. In this embodiment, themethod further includes providing a spray mold having a mold surfacesmaller than the outer surface of the major skin layer and sprayingpolyurethane material proximate the mold surface to form a sprayedurethane minor skin layer. In this embodiment, the method furtherincludes spraying a first portion of expandable polyurethane materialonto the minor skin layer to form a first resilient layer, placing amounting substrate onto the first resilient layer, and spraying a secondportion of expandable polyurethane material onto the first resilientlayer and the mounting substrate to form a second resilient layer. Inthis embodiment, the method further comprises removing the minor panelportion from the mold and securing the minor panel portion to the majorpanel portion.

In at least another embodiment, the method comprises providing a majorpanel having a major substrate, a sprayed urethane major skin layerdisposed over at least a portion of the major substrate, and a layer offoam between the major substrate and the major skin layer. In thisembodiment, the major panel has a mounting portion having at least onemounting opening. In this embodiment, the method further includesforming a minor panel by providing a spray mold having a mold surfacesmaller than the outer surface of the major skin layer and sprayingpolyurethane material proximate the mold surface to form a sprayedurethane minor skin layer having a height (H), an exterior surface. Inthis embodiment, the method further comprises and an interior surface,spraying a first portion of expandable polyurethane material onto theminor skin layer to form a first resilient layer, and spraying a secondportion of expandable polyurethane material onto the first resilientlayer and the mounting substrate to form a second resilient layer. Inthis embodiment, the method further comprises removing the minor panelfrom the mold and securing the minor panel to the mounting portion ofthe major panel. In this embodiment, the minor panel has a package space(X) disposed between the interior surface of the minor skin layer andthe mounting portion of the major substrate, with at least one of (i)the height (H) of the minor skin being less than 12 mm and (ii) thepackage space (X) being less than 5 mm.

In at least yet another embodiment, the method comprises providing amajor panel having a major substrate and major skin layer disposed overat least a portion of the major substrate, with the major substratehaving a mounting portion. In this embodiment, the method furthercomprises forming a minor panel by spraying polyurethane materialproximate a mold surface to form a sprayed urethane minor skin layerhaving a height (H), placing a mounting substrate proximate the minorskin layer, and spraying expandable polyurethane material over themounting substrate to form a resilient layer to secure the mountingsubstrate to the minor skin layer. In this embodiment, the methodfurther comprises securing the minor panel to the mounting portion ofthe major panel, wherein a package space (X) is present between theminor skin layer and the mounting portion. In this embodiment, at leastone of (i) the height (H) is less than 12 mm or (ii) the package space(X) is less than 5 mm.

While exemplary embodiments in accordance with the invention areillustrated and disclosed, such disclosure should not be construed tolimit the claims. It is anticipated that various modifications andalternative designs may be made without departing from the scope of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is perspective view of an instrument panel according to anembodiment of the invention for use in motor vehicle;

FIG. 2 is a cross sectional view of the panel taken along the line 2-2of FIG.

FIG. 3 is a view similar to FIG. 2 showing components of the panel is anunassembled state;

FIG. 4 is a schematic view of a spray mold and a spray assembly for usein forming a panel component of the panel of FIG. 1, wherein the sprayassembly is shown applying material on the tool to form a skin layer;

FIG. 5 is a schematic view of the tool showing application of expandablematerial onto the skin layer to form a portion of a resilient layer;

FIG. 6 is a schematic view of the tool showing application of a mountingsubstrate onto the portion of resilient layer shown in FIG. 5;

FIG. 7 is a schematic view of the tool showing application of expandablematerial onto the first resilient layer to form another portion of theresilient layer; and

FIG. 8 is a perspective view of a component illustrated in FIG. 6.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

As required, detailed embodiments of the present invention are disclosedherein. However, it is to be understood that the disclosed embodimentsare merely exemplary of the invention that may be embodied in variousalternative forms. The figures are not necessarily of scale, somefeatures may be exaggerated or minimized to show details of particularcomponents. Therefore specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for the claims and/or a representative basis forteaching one skilled in the art to variously employ the presentinvention. Moreover, except where otherwise expressly indicated, allnumerical quantities in this description and in the claims indicatingamounts of materials or conditions of reactions and/or use are to beunderstood as modified by the word “about” in describing the broaderscope of this invention. Practice within the numerical limits stated isgenerally preferred. Also, unless expressly stated to the contrary,percent “parts of,” and ratio values are by weight and the descriptionof a group or class of materials as suitable preferred for a givenpurpose in connection with the invention implies that mixtures of anytwo or more members of the group or class may be equally suitable orpreferred.

FIGS. 1 and 2 show a multi-piece interior vehicle trim component, suchas an instrument panel 10, according to the invention for use with amotor vehicle 12. In at least one embodiment, the instrument panel 10has a major panel 14 and a minor panel 16 connected to the major panel.

In at least one embodiment, the minor panel 16 has a size constraintthat makes employing a foam in place process to form a foam layer in theminor panel unreliable. Examples of such a constraint can be the minorpanel 16 having at least one of a height (H) of less than 12 mm or apackage space (X) having at least a portion of less than 5 mm. In atleast one embodiment, the minor panel 16 has a height (H) of 1-10 mm,and in yet another embodiment of 5-7 mm. In at least one embodiment, theminor panel 16 has at least a portion having a package space (X) of0.5-4 mm, and in yet other embodiments of 1-3 mm.

The minor panel 16 is shown in the Figures to have a rectangular shape.However, it should be understood that the minor panel 16 can have anysuitable shape, such as a U-shape, a thin walled block-shape, anS-shape, a V-shape, etc. Furthermore, while the vehicle trim componentis being illustrated as an instrument panel 10, it should be understoodthat the vehicle trim component could be other types of panels, such asdoors, consoles and other vehicle interior trim panels.

Referring to FIG. 2, in at least one embodiment, the major panel 14includes a rigid major substrate 20 having a first portion 22 and atleast one connector portion 24 extending from the first portion. Theconnector portion 24 includes a mounting opening 26.

As best shown in the embodiment illustrated in FIG. 3, the major panel24 has two connector or mounting portions, illustrated as tabs,extending from the rigid substrate 20. It should be understood that anynumber of connector portions 24 could be employed and that the connectorportions can take any suitable shape, such as a rectangular plate havingone or more mounting holes therein. Furthermore, the connector tabs 24,(i.e., connector portion) could extend elsewhere than from the majorsubstrate, so long as the connector portion can secure the minor panel16 relative to the major panel 14.

Referring again to FIG. 2, the major panel 14 further includes, in atleast one embodiment, a foam layer 28 secured to the major substrate 20and a major skin layer 32 secured to the foam layer 28 to cover the foamlayer 28 and provides an exterior apparent surface. As can be seen inFIG. 2, the major skin layer 32 can be provided with an end portion thatcontacts the first portion 22 of the major substrate 20 to act as a“foam shut-off.”

The major substrate 20 is a structural member that provides support forthe remainder of the major panel 14, and may comprise any suitablematerial. For example, the major substrate 20 may be made of plastic orreinforced plastic such as fiberglass reinforced polyurethane.Additional examples of suitable plastics, besides polyurethane, includepolypropylene, polyethylene, acrylonitrile butadiene styrene (ABS),polycarbonate (PC), and ABS/PC blends. In at least one embodiment, themajor substrate 14 may have a general thickness of between 0.5 to 5 mm,in another embodiment 1.0 to 3.5 mm, and in yet another embodiment 2.0to 3.0 mm.

In the illustrated embodiment, the foam layer 28 is adhered between themajor substrate 20 and the major skin layer 32. The foam layer 28generally contours to the major substrate 20. The foam layer 28 helps toprovide a soft feel to the major panel 14 of the instrument panel 10.The foam layer 28 may comprise any suitable foam material. For example,the foam layer 28 may comprise a foam in place polyurethane foam. In atleast one embodiment, the density of the foam layer 28 is in the rangeof 0.05 to 0.20 grams per cubic centimeter (g/cm³). In at least oneembodiment the foam layer 28 has a thickness of 3.0 to 25 mm, and in atleast another embodiment 5 to 15 mm, and in yet another embodiment 6 to10 mm. The foam layer 28 may have varying thicknesses.

The major skin layer 32 is adhered to the foam layer 28. Moreover, themajor skin layer 32 is configured to provide a covering over, and isgenerally contoured to, the foam layer 28 and may comprise anysufficiently dense material. For example, the major skin layer 32 may bea solid layer that comprises an aromatic or aliphatic compound. As amore specific example, the major skin layer 32 may be made of anelastomer such as polyurethane. As an even more specific example, themajor skin layer 32 may be sprayed urethane. Furthermore, the major skinlayer 32 may have any suitable thickness and density. For example, themajor skin layer 32 may have a general thickness in the range of 0.4 to3 mm and a density in the range of 0.85 to 1.2 g/cm³. In at least oneembodiment, the major skin layer 32 may have a shore A hardness of 50 to80. In at least one embodiment, the major skin layer 32 has a generalthickness in the range of 0.5 to 1.2 mm, and a density in the range of0.95 to 1.1 g/cm³.

An optional coating (not shown) may be disposed over the major skinlayer to protect the major skin layer 32 and/or to provide a decorativesurface for the instrument panel 10. For example, the optional coating(not shown) may be used to inhibit sunlight and/or other ultravioletlight from reaching the major skin layer 32. As another example, theoptional coating may be used as a paint to provide a desired colorand/or texture to the major panel 14. While the optional coating maycomprise any suitable material, in at least one embodiment of theinvention, the optional coating is made of an aliphatic polyurethanecomposition. Furthermore, the optional coating may have any suitablethickness, such as a thickness of approximately 0.5 to 1.5 mil.

The major panel 14 may be made in any suitable manner. In at least onesuitable manner, the major skin layer 32 is formed by spraying suitablematerial onto a spray mold. The major skin layer 32 is then secured tothe major substrate 20 via the foam layer 28. In at least oneembodiment, the foam layer 28 is disposed between the major skin layer32 and the major substrate 20 via a foam in place process.

Referring to FIG. 2, in at least one embodiment, the minor panel 16includes a minor skin layer 42, a resilient layer 44 disposed betweenthe minor skin layer 42 and the connector portion 24 of the majorsubstrate 20, and a mounting plate 46 adhered to the resilient layer 44and connected to the connector portion 24. As is shown in FIG. 2, spacemay be present, at least in certain locations, between the resilientlayer 44 and the connector portion 24.

The minor skin layer 42 is configured to provide a coating over, and isgenerally contoured to, the resilient layer 44. The minor skin layer 42can be made of the same or similar material as the major skin layer 32and may comprise any sufficiently dense sprayed urethane material. Forexample, the minor skin layer 42 may be a solid layer that comprises anaromatic or aliphatic compound. As a more specific example, the minorskin layer 42 may be made of an elastomer such as polyurethane. As aneven more specific example, the minor skin layer 42 may be sprayedurethane. Furthermore, the minor skin layer 42 may have any suitabledensity. For example, the minor skin layer 42 may have a density in therange of 0.85 to 1.2 g/cm³. In at least one embodiment, the minor skinlayer 42 has a density in the range of 0.95 to 1.1 g/cm³. In at leastone embodiment, the minor skin layer has a shore A hardness of 50 to 80.An optional coating (not shown) similarly with the major skin layer 32,could be applied over the minor skin layer 42.

In at least the illustrated embodiment, the minor skin layer 42 isthicker than the major skin layer 32. This may help to provide a morerigid part for dimensional stability. While the minor skin layer 42 mayhave any suitable thickness, in at least one embodiment, the minor skinlayer has an average thickness in the range of 0.3 to 8 mm, and inanother embodiment 0.4 to 3 mm, and in yet another embodiment of 0.5 to1.25 mm.

The mounting plate 46, in at least the illustrated embodiment as shownin FIG. 2, includes a plate portion 60 and at least one mountingprojection 62 depending from the plate 60. While two mountingprojections 62 are shown in FIGS. 3 and 8, it should be understood thatmore or less projections could be used, as desired. The mountingprojection 62 can be secured to the connector portion 24 via anysuitable connection means, such as by heat staking, as is shown in FIG.2.

In at least one embodiment, the mounting plate 46 includes a pluralityof, such as four, equidistant ribs 66 depending from plate portion 60and disposed about the projection to help securably mount and locate theprojection to the opening 26 and the connector portion 24. It should beunderstood that ribs 66 could be located on the connector portion 24either in addition to, or instead of, the ribs 66 on the plate portion60.

As best shown in FIG. 2, the plate portion 60 has a plurality ofopenings 68 therein. As will be explained further below, the openings 68can assist in securing the plate 60 to the resilient layer 44. Themounting plate 46 may be made of any suitable material such as plasticor metal. In at least one embodiment, the plate portion 60 has athickness of 0.2-3 mm, and in another embodiment 0.75-1.25 mm. In atleast one embodiment, the mounting plate 46 is made of the same or asimilar material as that of the major substrate 22.

The projections 62 on the mounting plate 46 can be secured to theconnector portion 24 of the substrate 20 via any suitable means, such asheat staking as is shown in FIG. 2. The distance between the mountingportion 24 and the minor skin layer 42 is known as the package space(X). As can be understood, a substantial portion or even all of thepackage space (X) could be less than 5 mm, and in at least anotherembodiment between 0.5 and 4 mm, and in yet at least another embodimentbetween 1 to 3 mm.

In the illustrated embodiment, the resilient layer 44 is adhered to themounting substrate 46 and the minor skin layer 42. The resilient layer44 may help to provide a soft feel to the minor panel 16. The resilientlayer 44 may comprise any suitable sprayed expanded polyurethanematerial. For example, the resilient layer 44 may comprise an expandedaromatic polyurethane elastomer. In at least one embodiment, the densityof the resilient layer 44 can be in the range of 0.1 to 0.75 g/cm³, inanother embodiment between 0.15 to 0.5 g/cm³, and in yet anotherembodiment 0.2 to 0.3 g/cm³.

In at least one embodiment, the resilient layer 44 primarily maycomprise a low permeable, relatively closed cell material. In at leastone embodiment, the resilient layer 44 may comprise 35 to 75 percentclosed cell structures, in at least another embodiment 40 to 65 percentclosed cell structures, and in yet at least another embodiment 45 to 55percent closed cell structures, based upon the entire resilient layer44. In at least one embodiment, the average cell structure size can varybetween 0.05 mm to 3.0 mm, and in yet other embodiments between 0.5 mmto 1.0 mm.

In at least the illustrated embodiment, the resilient layer 44 generallycomprises a first portion 52 adjacent the major skin layer 42 and asecond portion 54 generally behind the first portion 42 and adjacent theconnector portion 24. In at least one embodiment, the first portion 52of the resilient layer 44 may have an average thickness generallybetween 0.3 to 4.5 mm, in other embodiments between 1 to 4 mm and in yetother embodiments 2 to 3 mm. In at least one embodiment, the secondportion 54 of the resilient layer 44 may have an average thicknessgenerally between 0.3 to 3 mm, in other embodiments between 0.5 to 2 mmand in yet other embodiments 0.75 to 1.25 mm. It should be understoodthat the thicknesses of the portions 52 and 54 can vary from each other,as desired. Furthermore it should be understood that the thickness ofeach portion 52 and 54, and especially for 54, can vary throughout theirportion as desired, such as is dictated by part configuration.

Referring to FIGS. 4-6, a method of manufacturing the instrument panel10 will now be described. As set forth above, the major panel 14 is madevia any suitable process. The major panel 14 is made separately from theminor panel 16.

The minor panel 16 may be made by the following method. The method ofmaking the minor panel 16 may begin by spraying an optional mold releaseagent and then an optional coating (not shown) on a spraying mold tool70 using any suitable device, such as robotic low pressure (such as 10to 40 psi) spray assembly 72 having one or more moveable spray nozzles.

The tool 70 has a spray receiving surface 76 generally corresponding tothe exterior surface of the minor panel 14. The spray surface 76 has, inat least one embodiment, a height (H) of less than 12 mm, and in atleast another embodiment between 1 and 10 mm, and in yet at leastanother embodiment between 4 to 8 mm. The tool 70 may be heated to anysuitable temperature if desired.

Next, the method involves spraying skin layer forming material onto thespray receiving surface 76 (or the optional coating or the optional moldrelease agent) to form minor skin layer 42. A source of skin layerforming material (not shown) is in fluid communication with the sprayassembly 72. The skin layer forming material may be any suitablesprayable substance and may be applied using any suitable device. Forexample, the material may include polyol and isocyanate, and thematerial may be sprayed with a robotic high pressure (such as 400 to2,000 psi) spray assembly 72 having one or more moveable spray nozzles.As a result, the skin layer 42 may be formed of polyurethane. When theoptional coating (not shown) is omitted from the minor panel 14, theminor skin layer 44 is preferably a colored aliphatic polyurethane.

Referring to FIG. 5, in at least one embodiment the method then involvesintroducing expandable material onto the minor skin layer 42 to formresilient layer 44, which bonds to the minor skin layer 42. Theexpandable material may comprise any suitable expandable material. In atleast one embodiment, the expandable material comprises any suitableexpandable polyurethane material and may be applied in any suitablemanner. For example, the expandable polyurethane material may comprisepolyol, isocyanate and a blowing agent such as water and/or a readilyvolatile organic substance, such as a delayed-action amine catalyst.

Furthermore, the expandable material may be sprayed with a robotic sprayassembly 82 which receive the expandable material from a source ofexpandable material (not shown) in fluid communication with the sprayassembly 82. The robotic spray assembly 82 may include one or more spraynozzles and the material may be allowed to free rise to achieve adesired density. The robotic spray assembly 82 may be the same type ofspray assembly 72 as is used in FIG. 4. Alternatively, the same sprayassembly 72 as used in FIG. 4 could be used to spray the expandablematerial.

The resilient layer 44 adheres the mounting substrate 46 to the minorskin layer 42. In at least one embodiment, the expandable material issprayed in two steps to form the first portion 52 of the resilient layer44 and the second portion 54 of the resilient layers. In thisembodiment, a first portion of expandable material is sprayed onto theminor skin layer 42 to form a first portion 52 (FIG. 5) of the resilientlayer 44. Before the first portion of expandable material fully cures,the mounting plate 46 is placed on the first portion 52 of sprayedexpandable material. Next, a second portion of sprayed expandablematerial is sprayed over the mounting plate 60 of the mounting bracket46 and the first layer of sprayed expandable material. At this point,the first layer of sprayed expandable material may have already cured orat least partially cured into the first portion 52 of the resilientlayer 44. The second portion of the expandable material is sprayed to asufficient thickness to form a second portion 54 of resilient layer 44.The spraying of the second portion of the resilient layer is illustratedin FIG. 6. After the second portion of resilient layer 44 has cured, theminor panel 16 is formed as illustrated in FIG. 7. As can be seen in theFigures, the second portion 54 of resilient layer 44 may also fill theopenings 68 in the plate 60.

In at least one embodiment, the first portion 52 of the resilient layer44 may have an average thickness generally between 0.3 to 4.5 mm, inother embodiments between 1 to 4 mm and in yet other embodiments 2 to 3mm. In at least one embodiment, the second portion 54 of the resilientlayer 44 may have an average thickness generally between 0.3 to 3 mm, inother embodiments between 0.5 to 2 mm and in yet other embodiments 0.75to 1.25 mm. The minor panel 16 is then secured to the connector portion24 of the major substrate 22 in any suitable manner, such as by heatstaking the projection(s) 62 through the mounting opening(s) 26.

Referring to FIG. 8, a perspective view of one embodiment of mountingplate 46 is shown. Referring to FIG. 8, the mounting plate 46 includesopenings 68 in the plate 60 to allow expandable material to be sprayedtherethrough to help secure the mounting plate 46 and the second portion54 of resilient layer 44 to the first portion 52 of the resilient layer44.

In at least one embodiment, the present invention provides a soft touchsprayed skin panel having relatively even softness zones with consistentskin material to ensure consistent color, gloss and grain match.

Examples of other vehicle parts that may be manufactured by the abovemethod includes door panels, package shelves, pillar trim panels, trimproducts, door covers, console covers, shelves, and trim covers, amongothers.

Although separate spray assemblies 72 and 82 are shown in the figures,the spray assemblies may be provided as a single spray assembly.Furthermore if the material to be sprayed includes multiple substances,the substance may be mixed at a suitable time. For example, thesubstances may be mixed up stream of, within, or down stream of theassociated spray nozzles.

While embodiments of the invention have been illustrated and described,it is not intended that these embodiments illustrate and describe allpossible forms of the invention. Rather, the words used in thespecification are words of description rather than limitation, and it isunderstood that various changes may be made without departing from thespirit and scope of the invention.

1. A method for making a multi-piece vehicle interior trim panel, saidmethod comprising: providing a major panel having a major substrate, asprayed urethane major skin layer disposed over at least a portion ofthe major substrate, and a layer of foam between the major substrate andthe major skin layer, the major panel having a mounting portion havingat least one mounting opening; forming a minor panel, said minor panelbeing formed by: providing a spray mold having a mold surface smallerthan the outer surface of the major skin layer; spraying polyurethanematerial proximate the mold surface to form a sprayed urethane minorskin layer having a height (H), an exterior surface, and an interiorsurface; spraying a first portion of expandable polyurethane materialonto the minor skin layer to form a first resilient layer; placing amounting substrate onto the first resilient layer; and spraying a secondportion of expandable polyurethane material onto the first resilientlayer and the mounting substrate to form a second resilient layer;removing the minor panel from the mold; and securing the minor panel tothe mounting portion of the major panel, wherein a package space (X) isdisposed between the interior surface of the minor skin layer and themounting portion of the major substrate, with at least one of (i) theheight (H) of the minor skin being less than 12 mm and (ii) the packagespace (X) being less than 5 mm.
 2. The method of claim 1 wherein themounting substrate is placed onto the first resilient layer before thefirst resilient layer has substantially cured.
 3. The method of claim 1wherein the mounting substrate has at least one projection and whereinsecuring the minor panel to the major panel comprises inserting theprojection through the mounting opening of the major panel and securingthe projection to the major panel.
 4. The method of claim 3 wherein themounting substrate comprises a plate, the projection extending from theplate, the plate having at least one plate opening therein.
 5. Themethod of claim 4 wherein spraying a second portion of expandablepolyurethane material onto the first resilient layer and the mountingsubstrate comprises spraying the second portion onto the plate andthrough the plate opening.
 6. The method of the claim 3 wherein theprojection is heat-staked to the major panel portion.
 7. The method ofclaim 4 wherein the resilient layers each have a density of 0.1 to 0.75g/cm³.
 8. The method of claim 7 wherein the skin layer each have adensity of 0.85 to 1.2 g/cm³.
 9. The method of claim 7 wherein the firstresilient layer has an average thickness of 0.3-4.5 mm.
 10. The methodof claim 9 wherein the second resilient layer has an average thicknessof 0.3 to 3 mm.
 11. The method of claim 10 wherein the minor skin layerhas a n average thickness of 0.3 to 8 mm.
 12. The method of claim 11wherein the plate has a thickness of 0.2 to 3 mm.
 13. An automobileinterior panel made by the method of claim
 1. 14. An automobileinstrument panel made by the method of claim
 1. 15. A method for makinga multi-piece vehicle interior trim panel, said method comprising:providing a major panel having a major substrate and major skin layerdisposed over at least a portion of the major substrate, the majorsubstrate having a mounting portion; forming a minor panel, said minorpanel being formed by: spraying polyurethane material proximate a moldsurface to form a sprayed urethane minor skin layer having a height (H);placing a mounting substrate proximate the minor skin layer; andspraying expandable polyurethane material over the mounting substrate toform a resilient layer to secure the mounting substrate to the minorskin layer; and securing the minor panel to the mounting portion of themajor panel, wherein a package space (X) is present between the minorskin layer and the mounting portion, with at least one of the height (H)being less than 12 mm or the package space (X) being less than 5 mm. 16.The method of claim 15 wherein the mounting substrate has at least oneprojection and wherein securing the minor panel to the major panelcomprises securing the projection to mounting portion of the majorpanel.
 17. The method of claim 15 wherein the minor skin layer has anaverage thickness of 0.3 to 8 mm.
 18. The method of claim 15 wherein theresilient layers each have a density of 0.1 to 0.75 g/cm³.
 19. Themethod of claim 18 wherein the skin layer each have a density of 0.85 to1.2 g/cm³.
 20. A method for making a multi-piece vehicle interior trimpanel, said method comprising: providing a major panel having a majorsubstrate and sprayed urethane major skin layer disposed over at least aportion of the major substrate, the major panel having at least onemounting opening; forming a minor panel, said minor panel being formedby: providing a spray mold having a mold surface smaller than the outersurface of the major skin layer; spraying polyurethane materialproximate the mold surface to form a polyurethane skin layer; spraying afirst portion of expandable polyurethane material onto the skin layer toform a first resilient layer; placing a mounting substrate proximate thefirst resilient layer; and spraying a second portion of expandablepolyurethane material onto the first resilient layer and the mountingsubstrate to form a second resilient layer; and securing the minor panelto the major panel.